JP5157716B2 - Method for manufacturing universal joint yoke - Google Patents

Method for manufacturing universal joint yoke Download PDF

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JP5157716B2
JP5157716B2 JP2008191302A JP2008191302A JP5157716B2 JP 5157716 B2 JP5157716 B2 JP 5157716B2 JP 2008191302 A JP2008191302 A JP 2008191302A JP 2008191302 A JP2008191302 A JP 2008191302A JP 5157716 B2 JP5157716 B2 JP 5157716B2
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length
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JP2010023112A (en
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信行 萩原
慶一 堀野
一登 小林
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日本精工株式会社
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この発明は、同一直線上に存在しない1対の回転軸の端部同士を連結して、これら両回転軸同士の間で回転力の伝達を可能とする自在継手を構成するヨークの製造方法に関する。   The present invention relates to a method for manufacturing a yoke that constitutes a universal joint that connects ends of a pair of rotating shafts that do not exist on the same straight line, and enables transmission of rotational force between the rotating shafts. .
例えば自動車用操舵装置は、ステアリングシャフト及び中間軸等の複数本の回転軸を、自在継手を介して互いに直列に連結する事により構成している。この様な場合に使用する自在継手として従来から、十字軸により1対のヨーク同士を変位自在に連結して成る、カルダン継手と呼ばれる自在継手が、広く使用されている。又、この様な自在継手を構成するヨークを、鋼板等、十分な剛性を有する金属板に塑性加工を施す事により造る事も、従来から広く行われている。   For example, an automobile steering apparatus is configured by connecting a plurality of rotating shafts such as a steering shaft and an intermediate shaft in series via a universal joint. Conventionally, as a universal joint used in such a case, a universal joint called a cardan joint, in which a pair of yokes are displaceably connected by a cross shaft, has been widely used. In addition, it has been widely practiced to produce a yoke constituting such a universal joint by subjecting a metal plate having sufficient rigidity, such as a steel plate, to plastic working.
図12は、この様にして造られた自在継手用ヨークの1例として、特許文献1に記載されものを示している。このヨーク1は、欠円筒状の結合筒部2と、この結合筒部2の円周方向両端縁から連続して形成された1対のフランジ部3、4と、上記結合筒部2の先端縁の円周方向反対側となる2個所位置から連続して形成された1対の腕部5、5とを備える。このうちの結合筒部2は、上記ヨーク1を固定すべき図示しない回転軸の端部を挿入する部位である。この結合筒部2の内周面には、雌セレーション6を形成しており、この雌セレーション6を、上記回転軸の端部外周面に形成した雄セレーションに係合させる事で、上記ヨーク1と上記回転軸との相対回転を防止できる様にしている。   FIG. 12 shows what is described in Patent Document 1 as an example of a universal joint yoke manufactured as described above. The yoke 1 includes a coupling cylindrical portion 2 having a cylindrical shape, a pair of flange portions 3 and 4 formed continuously from both circumferential edges of the coupling cylindrical portion 2, and the distal end of the coupling cylindrical portion 2. A pair of arms 5 and 5 formed continuously from two positions on the opposite sides of the edge in the circumferential direction. Of these, the coupling cylinder portion 2 is a portion into which an end portion of a rotating shaft (not shown) to which the yoke 1 is to be fixed is inserted. A female serration 6 is formed on the inner peripheral surface of the coupling cylinder portion 2, and the female serration 6 is engaged with the male serration formed on the outer peripheral surface of the end portion of the rotating shaft, whereby the yoke 1 And relative rotation between the rotation axis and the rotation shaft can be prevented.
又、上記両フランジ部3、4のうちの一方のフランジ部3には、図示しないボルトの杆部を挿通する為の通孔7を、他方のフランジ部4には、このボルトの雄ねじ部を螺合させる為の、上記通孔7と同心のねじ孔8を、それぞれ形成している。又、上記両腕部5、5の先端部には、互いに同心の円孔9、9を形成している。上記ヨーク1と十字軸10とを組み合わせて自在継手を構成する場合には、上記各円孔9、9内に軸受カップ11、11を圧入する。これら各軸受カップ11、11は、ラジアルニードル軸受の外輪として機能し、上記ヨーク1に対して十字軸10を、揺動変位自在に結合支持する。   Further, one of the flange portions 3 and 4 has a flange 7 through which a bolt flange (not shown) is inserted, and the other flange portion 4 has a male screw portion of the bolt. A screw hole 8 concentric with the through-hole 7 for screwing is formed. Further, concentric circular holes 9 and 9 are formed at the distal ends of the both arm portions 5 and 5. When the universal joint is configured by combining the yoke 1 and the cross shaft 10, the bearing cups 11 and 11 are press-fitted into the circular holes 9 and 9. Each of these bearing cups 11 and 11 functions as an outer ring of a radial needle bearing, and couples and supports the cross shaft 10 to the yoke 1 so as to be swingable and displaceable.
上述の様なヨーク1の製造作業は、従来、図13に示す様に行っていた。先ず、鋼板等、十分な剛性を有する金属板をプレス加工で打ち抜く事により、図13の(A)に示す様な形状を有する、第一中間素材12を造る。この第一中間素材12は、長矩形状の主板部13と、この主板部13の幅方向片端縁の中間部2個所位置から突出した1対の舌片部14、14とを備える。この様な第一中間素材12は、1対のプレス型同士の間で押圧する事により、同図の(B)に示す様な形状に塑性変形させて、第二中間素材15とする。そして、同図の(B)→(C)→(D)の順に示す様に、上記第二中間素材15を構成する主板部13の長さ方向中間部を二段階に分けて湾曲させる事により、この長さ方向中間部を結合筒部2とし、且つ、上記主板部13の長さ方向両端部を1対のフランジ部3、4とし、且つ、上記両舌片部14、14を1対の腕部5、5とした、第三中間素材16を造る。そして、この第三中間素材16を構成する結合筒部2の内周面に雌セレーション6(図12)を、1対のフランジ部3、4に通孔7及びねじ孔8(図12)を、1対の腕部5、5の先端部に円孔9、9(図12)を、それぞれ形成して、上記ヨーク1を完成させる。   The manufacturing operation of the yoke 1 as described above has been conventionally performed as shown in FIG. First, a first intermediate material 12 having a shape as shown in FIG. 13A is made by punching a metal plate having sufficient rigidity, such as a steel plate, by press working. The first intermediate material 12 includes a long rectangular main plate portion 13 and a pair of tongue pieces 14 and 14 projecting from two intermediate portion positions of one end edge in the width direction of the main plate portion 13. Such a first intermediate material 12 is plastically deformed into a shape as shown in (B) of the same figure by pressing between a pair of press dies to form a second intermediate material 15. Then, as shown in the order of (B) → (C) → (D) in the figure, the intermediate portion in the longitudinal direction of the main plate portion 13 constituting the second intermediate material 15 is bent in two stages. The lengthwise intermediate portion is the coupling cylinder portion 2, the longitudinal end portions of the main plate portion 13 are a pair of flange portions 3, 4, and the tongue portions 14, 14 are a pair. The third intermediate material 16 having the arms 5 and 5 is made. A female serration 6 (FIG. 12) is provided on the inner peripheral surface of the coupling cylinder portion 2 constituting the third intermediate material 16, and a through hole 7 and a screw hole 8 (FIG. 12) are provided on the pair of flange portions 3 and 4. Circular holes 9 and 9 (FIG. 12) are respectively formed at the tip portions of the pair of arm portions 5 and 5 to complete the yoke 1.
ところで、上述した様なヨーク1の場合には、このヨーク1の強度及び剛性を十分に確保する観点より、1対のフランジ部3、4全体の板厚を、他の部位の板厚よりも大きくする構造を採用するのが好ましい。この様な構造は、例えば上述の図13に示したヨーク1の製造方法に於いて、(A)又は(B)の状態で、主板部13の長さ方向両端部(完成後に上記1対のフランジ部3、4となる部分)の板厚を増加させる工程を追加する事により、実現できる。但し、この板厚を増加させる、具体的且つ実用的な方法に就いては、従来は知られていなかった。   By the way, in the case of the yoke 1 as described above, from the viewpoint of sufficiently ensuring the strength and rigidity of the yoke 1, the thickness of the entire pair of flange portions 3 and 4 is made larger than the thickness of the other portions. It is preferable to employ a structure for increasing the size. Such a structure is obtained, for example, in the manufacturing method of the yoke 1 shown in FIG. 13 described above, in the state (A) or (B), both ends in the length direction of the main plate part 13 (the pair of the above after completion). This can be realized by adding a step of increasing the plate thickness of the flange portions 3 and 4. However, a specific and practical method for increasing the plate thickness has not been conventionally known.
例えば、金属板素材の一部の板厚を増加する方法として従来から、特許文献2に記載された方法が知られている。この特許文献2に記載された方法の場合には、先ず、図14の(A)→(B)に示す様に、金属板素材17の縁部分を曲げ起こす事により、この縁部分に曲げ起こし部18を形成する。次いで、同図の(B)→(C)に示す様に、この曲げ起こし部18を図示しない上下型で押し潰す事により、上記金属板素材17の縁部分に厚肉部19を形成する事で、この縁部分の板厚を増加させる。ところが、この様な特許文献2に記載された方法の場合には、上記金属板素材17の縁部分の様な、比較的狭い領域の板厚を所望通りの大きさに増加させるのは容易であるが、上述した主板部13の長さ方向両端部の様な、比較的広い領域の板厚を所望通りの大きさに増加させるのは難しい。この為、上記特許文献2に記載された方法を、上記主板部13の長さ方向両端部の板厚を増加させる方法として採用するのは難しい。
尚、本発明に関連する公知文献として、以下の特許文献3がある。
For example, a method described in Patent Document 2 is conventionally known as a method for increasing the thickness of a part of a metal plate material. In the case of the method described in Patent Document 2, first, as shown in FIG. 14 (A) → (B), the edge portion of the metal plate material 17 is bent and raised to the edge portion. Part 18 is formed. Next, as shown in FIG. 5B → C, the bent portion 18 is crushed by an upper and lower mold (not shown) to form a thick portion 19 at the edge portion of the metal plate material 17. Thus, the thickness of the edge portion is increased. However, in the case of the method described in Patent Document 2, it is easy to increase the thickness of a relatively narrow region such as the edge portion of the metal plate material 17 to a desired size. However, it is difficult to increase the plate thickness in a relatively wide area such as the above-described both ends in the length direction of the main plate portion 13 to a desired size. For this reason, it is difficult to employ the method described in Patent Document 2 as a method of increasing the plate thickness at both ends in the length direction of the main plate portion 13.
In addition, there exists the following patent document 3 as a well-known literature relevant to this invention.
特開2004−223616号公報JP 2004-223616 A 特開平7−155883号公報Japanese Patent Laid-Open No. 7-155883 特開平3−41220号公報JP-A-3-41220
本発明の自在継手用ヨークの製造方法は、上述の様な事情に鑑み、素材となる金属板を打ち抜き加工する事により造った中間素材を用いて、1対のフランジ部の板厚を他の部位の板厚よりも大きくしたヨークを、能率良く、しかも十分な精度を確保して造れる方法を実現すべく発明したものである。   In view of the circumstances as described above, the method for manufacturing a universal joint yoke according to the present invention uses an intermediate material made by punching a metal plate as a material to change the thickness of a pair of flange portions to other thicknesses. The present invention was invented to realize a method for producing a yoke having a thickness larger than the thickness of the portion with high accuracy and sufficient accuracy.
本発明の自在継手用ヨークの製造方法は、先ず、素材となる金属板に打ち抜き加工を施す事により、少なくとも長矩形状の主板部を備えた中間素材(例えば、この主板部と、この主板部の幅方向片端縁の中間部2個所位置から突出した1対の舌片部とを備えた中間素材)を造る。
その後、上記主板部の長さ方向中間部を湾曲させる事により、この長さ方向中間部を、自在継手用ヨークを構成する欠円筒状の結合筒部とし、且つ、上記主板部の長さ方向両端部をそれぞれ、この結合筒部の円周方向両端縁から連続して形成された、上記自在継手用ヨークを構成する1対のフランジ部とする(更には、上記両舌片部をそれぞれ、上記結合筒部の先端縁の径方向反対側となる2個所位置から連続して形成された1対の腕部とする)。
特に、本発明の自在継手用ヨークの製造方法に於いては、上記結合筒部を完成させる前に、上記主板部の各部分に、これら各部分毎に設定した所定の大きさのクッション力を、これら各部分の厚さ方向に加えながら、上記主板部に長さ方向両側から圧縮力を加える。この様な増肉加工を施す事により、この圧縮力に基づいてこの主板部が座屈するのを防止すると共に、この主板部の各部分の板厚の増加量を調整する。そして、上記主板部の長さ方向両端部の板厚を、この主板部の長さ方向中間部の板厚と異なる大きさに増加させる。
The method for manufacturing a universal joint yoke according to the present invention includes firstly punching a metal plate as a raw material, so that an intermediate material having at least a long rectangular main plate portion (for example, the main plate portion and the main plate portion An intermediate material having a pair of tongue pieces projecting from two positions of the middle part of one edge in the width direction is made.
After that, by curving the lengthwise intermediate portion of the main plate portion, this lengthwise intermediate portion is used as a non-cylindrical connecting tube portion constituting the universal joint yoke, and the length direction of the main plate portion Both end portions are respectively formed as a pair of flange portions constituting the universal joint yoke formed continuously from both circumferential edges of the coupling cylinder portion. A pair of arms formed continuously from two positions on the opposite side in the radial direction of the leading edge of the coupling cylinder).
In particular, in the method for manufacturing a universal joint yoke according to the present invention, before the coupling cylinder part is completed, a cushioning force having a predetermined size set for each part is applied to each part of the main plate part. While applying the thickness direction of each of these portions, a compressive force is applied to the main plate portion from both sides in the length direction. By performing such a thickening process, the main plate portion is prevented from buckling based on the compressive force, and the increase amount of the thickness of each portion of the main plate portion is adjusted. And the plate | board thickness of the longitudinal direction both ends of the said main plate part is made to increase to a magnitude | size different from the plate | board thickness of the longitudinal direction intermediate part of this main plate part.
この様な特徴を有する本発明を実施する場合には、例えば請求項2に記載した方法を採用する事ができる。この請求項2に記載した方法の場合には、増肉加工を施す前に、主板部の長さ方向中間部に絞り加工を施す事により、この長さ方向中間部を完成後の結合筒部と同方向に湾曲した部分円筒状に変形させる。その後、この長さ方向中間部の形状を保持する為に、この長さ方向中間部に対し、この長さ方向中間部の両側からこの長さ方向中間部に向かう材料の流れを確実に堰き止められる大きさのクッション力を加えながら、上記増肉加工を施す。   In carrying out the present invention having such characteristics, for example, the method described in claim 2 can be adopted. In the case of the method described in claim 2, before the thickening process is performed, the lengthwise intermediate part is drawn to the intermediate part in the longitudinal direction of the main plate part, so that the combined cylindrical part after completion of the lengthwise intermediate part is obtained. And deformed into a partially cylindrical shape curved in the same direction. After that, in order to maintain the shape of the intermediate portion in the longitudinal direction, the material flow from both sides of the intermediate portion in the longitudinal direction to the intermediate portion in the longitudinal direction is reliably dammed to the intermediate portion in the longitudinal direction. The above thickening process is performed while applying a cushioning force of a size that can be obtained.
又、上述した様な特徴を有する本発明を実施する場合には、例えば請求項3に記載した方法を採用する事もできる。この請求項3に記載した方法の場合には、主板部の長さ方向中間部に、この長さ方向中間部を完成後の結合筒部と同方向に湾曲した部分円筒状に変形させる絞り加工を施し始めるのと同時に、又は、この絞り加工の途中から、増肉加工を開始する。これにより、この増肉加工の開始後、上記絞り加工が終了する迄の間中、上記主板部の板厚を、この主板部の長さ方向両端部と長さ方向中間部とで、互いに同じ割合で増加させる。これと共に、上記絞り加工が終了した後、上記主板部の長さ方向中間部の形状を保持する為に、この絞り加工で使用したダイスと絞りパンチとを用いて、この長さ方向中間部に対し、この長さ方向中間部の両側からこの長さ方向中間部に向かう材料の流れを確実に堰き止められる大きさのクッション力を加えながら、上記増肉加工を続行する。これにより、上記主板部の長さ方向両端部の板厚を、この主板部の長さ方向中間部の板厚よりも大きな値にまで増加させる。   Moreover, when implementing this invention which has the above characteristics, the method of Claim 3, for example can also be employ | adopted. In the case of the method described in claim 3, the drawing process is performed in which the longitudinal intermediate portion is deformed into a partially cylindrical shape curved in the same direction as the combined cylindrical portion after completion in the longitudinal intermediate portion of the main plate portion. The thickening process is started simultaneously with the start of application or during the drawing process. As a result, the thickness of the main plate portion is the same between the lengthwise both ends and the lengthwise intermediate portion of the main plate portion from the start of the thickening process until the drawing process is completed. Increase in proportion. At the same time, after the drawing process is finished, in order to maintain the shape of the lengthwise intermediate part of the main plate part, the die and the drawing punch used in the drawing process are used, On the other hand, the above-described thickening process is continued while applying a cushioning force large enough to dam the flow of the material from both sides of the longitudinal intermediate portion toward the longitudinal intermediate portion. As a result, the plate thickness at both end portions in the length direction of the main plate portion is increased to a value larger than the plate thickness at the intermediate portion in the length direction of the main plate portion.
又、上述した様な特徴を有する本発明を実施する場合には、例えば請求項4に記載した方法を採用する事もできる。この請求項4に記載した方法の場合には、主板部の長さ方向中間部とその両側部分とに、互いに異なる大きさのクッション力を加えながら増肉加工を行う。これにより、上記主板部の長さ方向中間部の板厚と、長さ方向両端部の板厚とを、それぞれ増加させると共に、この長さ方向中間部の板厚の増加量と、この長さ方向両端部の板厚の増加量とを、互いに異ならせる。   Moreover, when implementing this invention which has the above characteristics, the method of Claim 4 can also be employ | adopted, for example. In the case of the method according to the fourth aspect, the thickening process is performed while applying cushioning forces having different sizes to the intermediate portion in the longitudinal direction of the main plate portion and both side portions thereof. As a result, the plate thickness at the intermediate portion in the longitudinal direction of the main plate portion and the plate thickness at both ends in the longitudinal direction are respectively increased, and the amount of increase in the plate thickness at the intermediate portion in the longitudinal direction and the length thereof are increased. The amount of increase in thickness at both ends in the direction is made different from each other.
更に、上述した様な特徴を有する本発明を実施する場合には、例えば請求項5に記載した方法を採用する事ができる。この請求項5に記載した方法の場合、主板部の各部分に加えるクッション力は、この主板部をダイスの上面に載せた状態で、この主板部の上面の各部分をクッション部材若しくは絞りパンチにより押圧する事に基づいて発生させる。又、このクッション部材若しくは絞りパンチを押圧する力は、プレス機を構成するプレスラムの下方への変位力を、方向変換せずに利用して得る。これに対し、上記主板部に加える圧縮力は、この主板部の長さ方向両端縁を1対の増肉パンチにより押圧する事に基づいて発生させる。又、これら両増肉パンチを押圧する力は、上記プレスラムの下方への変位力を、水平方向の変位力に変換する事により得る。
尚、この様な請求項5に記載した方法を採用する場合、上記主板部に圧縮力を加える事によって生じる、この主板部の板厚の増加量は、プレス機を構成するプレスラムのストロークに凡そ比例する。この為、この主板部の板厚の増加量は、このプレスラムのストロークと相関関係のある、上記プレス機のダイハイトを調整する事によって、調整できる。
Furthermore, when implementing the present invention having the above-described features, for example, the method described in claim 5 can be employed. In the case of the method described in claim 5, the cushioning force applied to each part of the main plate part is determined by applying a cushion member or a drawing punch to each part of the upper surface of the main plate part while the main plate part is placed on the upper surface of the die. Generate based on pressing. Moreover, the force which presses this cushion member or an aperture punch is obtained using the downward displacement force of the press ram which comprises a press machine, without changing direction. On the other hand, the compressive force applied to the main plate portion is generated based on pressing both ends in the length direction of the main plate portion with a pair of thickening punches. Moreover, the force which presses these both thickening punches is obtained by converting the downward displacement force of the said press ram into the displacement force of a horizontal direction.
When the method described in claim 5 is adopted, the increase in the plate thickness of the main plate portion caused by applying a compressive force to the main plate portion is approximately the stroke of the press ram constituting the press machine. Proportional. Therefore, the amount of increase in the plate thickness of the main plate portion can be adjusted by adjusting the die height of the press machine, which is correlated with the stroke of the press ram.
上述した様な本発明の自在継手用ヨークの製造方法によれば、素材となる金属板を打ち抜き加工する事により造った中間素材を用いて、1対のフランジ部の板厚を他の部位の板厚よりも大きくしたヨークを、能率良く、しかも十分な精度を確保して造れる。   According to the method for manufacturing a universal joint yoke of the present invention as described above, the thickness of a pair of flange portions is set to other parts by using an intermediate material made by punching a metal plate as a material. A yoke larger than the plate thickness can be manufactured efficiently and with sufficient accuracy.
[実施の形態の第1例]
図1〜4は、請求項1〜2に対応する、本発明の実施の形態の第1例を示している。本例の製造対象となる自在継手用のヨーク1aは、前述の図12に示した従来のヨーク1と同様、欠円筒状の結合筒部2aと、この結合筒部2aの円周方向両端縁から連続して形成された1対のフランジ部3a、4aと、上記結合筒部2aの先端縁の円周方向反対側となる2個所位置から連続して形成された1対の腕部5a、5aとを備える。そして、このうちの結合筒部2aの内周面に雌セレーション6を、上記両フランジ部3a、4aに互いに同心の通孔7及びねじ孔8を、上記両腕部5a、5aの先端部に互いに同心の円孔9、9を、それぞれ形成している。特に、本例の製造対象となるヨーク1aの場合には、上記両フランジ部3a、4aの板厚を、他の部位の板厚よりも大きくしている。
[First example of embodiment]
1-4 show a first example of an embodiment of the present invention corresponding to claims 1 and 2. The universal joint yoke 1a to be manufactured in this example is similar to the conventional yoke 1 shown in FIG. 12 described above, and has a cylindrical coupling cylinder portion 2a and both circumferential edges of the coupling cylinder portion 2a. A pair of flange portions 3a, 4a continuously formed from a pair of arm portions 5a formed continuously from two positions on the opposite side in the circumferential direction of the tip edge of the coupling tube portion 2a, 5a. Of these, the female serration 6 is formed on the inner peripheral surface of the coupling cylinder portion 2a, the through holes 7 and the screw holes 8 are concentric with the flange portions 3a and 4a, and the distal ends of the arm portions 5a and 5a. Concentric circular holes 9 and 9 are formed respectively. In particular, in the case of the yoke 1a to be manufactured in this example, the plate thicknesses of the flange portions 3a and 4a are made larger than the plate thicknesses of the other portions.
本例の場合、上記ヨーク1aを製造する際には、先ず、素材となる金属板である、SPHC、SPHD、SPHEの如き熱間圧延軟鋼板等の鋼板に対し、「打ち抜き工程」→「絞り工程」→「増肉工程」→「腕部成形工程」→「曲げ工程」の順で、それぞれ所定の加工を施す。以下、これら各工程の具体的な内容に就いて、上記の順に従って説明する。   In the case of this example, when manufacturing the yoke 1a, first, a “punching process” → “drawing” is performed on a steel plate such as a hot rolled mild steel plate such as SPHC, SPHD, SPHE, which is a metal plate. Predetermined processing is performed in the order of “process” → “thickening process” → “arm part forming process” → “bending process”. Hereinafter, the specific contents of these steps will be described in the order described above.
先ず、上記「打ち抜き工程」では、上記鋼板をプレス加工で打ち抜く事により、図2の(A)に示す様な第一中間素材12aを得る。この第一中間素材12aは、長矩形状の主板部13aと、この主板部13aの幅方向片端縁の中間部2個所位置から突出した1対の舌片部14a、14aとを備える。尚、本例の場合、上記第一中間素材12aの板厚(上記鋼板の厚さ)Tは6〜8mmであり、上記主板部13aの長さLは130〜150mmであり、同じく幅Wは30〜50mmである。   First, in the “punching step”, the first intermediate material 12a as shown in FIG. 2A is obtained by punching the steel plate by press working. The first intermediate material 12a includes a long rectangular main plate portion 13a and a pair of tongue piece portions 14a and 14a protruding from positions of two intermediate portions of one end edge in the width direction of the main plate portion 13a. In the case of this example, the plate thickness (the thickness of the steel plate) T of the first intermediate material 12a is 6 to 8 mm, the length L of the main plate portion 13a is 130 to 150 mm, and the width W is the same. 30-50 mm.
次に、上記「絞り工程」では、図2の(A)→(B)、及び、図3の(A)→(B)に示す様に、上記第一中間素材12aを構成する主板部13aの長さ方向中間部に絞り加工を施す事により、この長さ方向中間部に、完成後の結合筒部2a{図1及び後述する図2の(E)}と同方向に湾曲した部分円筒状の絞り部21を形成する事で、第二中間素材20を得る。この絞り部21の曲率半径は、完成後の結合筒部2aの曲率半径よりも少しだけ大きくしている。この様な「絞り工程」の目的は、上記第一中間素材12aを上記ヨーク1aの完成形状に近づける事、及び、次述する「増肉工程」で、上記主板部13aの長さ方向両端部(完成状態で上記両フランジ部3a、4aとなる部分)のみを増肉し易くする事、及び、後述する「曲げ工程」で、上記主板部13aの長さ方向中間部の曲げ量を減らせる様にして、この長さ方向中間部に割れが発生するのを防止する事にある。   Next, in the “drawing step”, as shown in FIGS. 2 (A) → (B) and FIG. 3 (A) → (B), the main plate portion 13a constituting the first intermediate material 12a. A partial cylinder curved in the same direction as the completed combined cylinder portion 2a {FIG. 1 and FIG. 2 (E)} is drawn on the intermediate portion in the longitudinal direction by drawing the longitudinal intermediate portion. The second intermediate material 20 is obtained by forming the shaped throttle portion 21. The radius of curvature of the narrowed portion 21 is slightly larger than the radius of curvature of the combined cylinder portion 2a after completion. The purpose of such a “drawing step” is to bring the first intermediate material 12a closer to the completed shape of the yoke 1a and to the both ends of the main plate portion 13a in the longitudinal direction in the “thickening step” described below. It is possible to easily increase the thickness of only the flange portions 3a and 4a in the completed state, and to reduce the bending amount of the intermediate portion in the longitudinal direction of the main plate portion 13a by a “bending step” described later. In this way, it is to prevent the occurrence of cracks in the intermediate portion in the length direction.
上記「絞り工程」で使用する装置(プレス機)は、図3に示す様に、ダイス22と、ホルダ23と、1対のサイドクッション部材24、24と、絞りパンチ25とを備える。上記主板部13aの長さ方向中間部に絞り加工を施す場合には、図3の(A)に示す様に、上記ダイス22の上面に上記第一中間素材12aを載せると共に、上記ホルダ23によりこの第一中間素材12aの外周を拘束して、この第一中間素材12aの水平方向の位置決めを図る。更に、この第一中間素材12aを構成する主板部13aのうち、絞り加工を施す部分である長さ方向中間部の両側部分の上面を、上記1対のサイドクッション部材24、24により押える。そして、この状態で、これら両サイドクッション部材24、24同士の間に配置された、上記絞りパンチ25により、上記主板部13aの長さ方向中間部に上方からの絞り加工力を加える。これにより、図3の(A)→(B)に示す様に、上記絞りパンチ25の下面に設けた凸部26と、上記ダイス22の上面に設けた凹部27との間で、上記主板部13aの長さ方向中間部を塑性変形させる事により、上記絞り部21を形成する(上記第二中間素材20を得る)。   As shown in FIG. 3, the apparatus (pressing machine) used in the “drawing step” includes a die 22, a holder 23, a pair of side cushion members 24 and 24, and a drawing punch 25. When drawing the intermediate portion in the longitudinal direction of the main plate portion 13a, the first intermediate material 12a is placed on the upper surface of the die 22 as shown in FIG. The outer periphery of the first intermediate material 12a is constrained to position the first intermediate material 12a in the horizontal direction. Further, of the main plate portion 13a constituting the first intermediate material 12a, the upper surfaces of both side portions of the intermediate portion in the longitudinal direction, which is a portion to be drawn, are pressed by the pair of side cushion members 24, 24. In this state, the drawing punching force from above is applied to the intermediate portion in the longitudinal direction of the main plate portion 13a by the drawing punch 25 disposed between the side cushion members 24, 24. Accordingly, as shown in FIGS. 3A to 3B, the main plate portion is formed between the convex portion 26 provided on the lower surface of the drawing punch 25 and the concave portion 27 provided on the upper surface of the die 22. The narrowed portion 21 is formed by plastically deforming the lengthwise intermediate portion 13a (the second intermediate material 20 is obtained).
尚、この様な絞り加工を行う際に、上記両サイドクッション部材24、24を設けていなかったり、設けていたとしても、これら両サイドクッション部材24、24のクッション力(上記主板部13aの上面を押える力)が弱く{9.8kN(1.0tonf)以下に}なっていたりすると、上記主板部13aの長さ方向両側部分が、図3の(B)に矢印イ、イで示す方向に浮き上がって、V字形になってしまう。そこで、本例では、この様な不具合が発生するのを防止する為に、上記両サイドクッション24、24の初期のクッション力を、それぞれ14.7kN(1.5tonf)以上(例えば14.7kN)に設定している。尚、本例の場合、上記両サイドクッション部材24、24のクッション力は、プレス機を構成する図示しないプレスラムの下方への変位力を、方向変換せずに利用して(例えば、適切なガススプリング、コイルスプリング等を選定し、これらによって所望値に調整する事により)得ている。上記絞り加工の終了後は、上記両サイドクッション部材24、24及び上記絞りパンチ25を上昇させると共に、上記ダイス22の内部に設けたノックピン37を上昇させる事により、上記第二中間素材20を取り出す。   Even when the side cushion members 24, 24 are not provided or are provided when performing such drawing processing, the cushioning force (the upper surface of the main plate portion 13a) of the side cushion members 24, 24 is provided. 3), the both sides of the main plate portion 13a in the direction indicated by arrows A and B in FIG. 3 (B). It floats up and becomes V-shaped. Therefore, in this example, in order to prevent the occurrence of such a problem, the initial cushioning force of the side cushions 24, 24 is 14.7 kN (1.5 tonf) or more (for example, 14.7 kN). Is set. In the case of this example, the cushioning force of the both side cushion members 24, 24 is obtained by utilizing the downward displacement force of a press ram (not shown) constituting the press machine without changing the direction (for example, appropriate gas It is obtained by selecting springs, coil springs, etc. and adjusting them to the desired value). After completion of the drawing, the side cushion members 24 and 24 and the drawing punch 25 are raised, and the knock pin 37 provided inside the die 22 is raised to take out the second intermediate material 20. .
次に、前記「増肉工程」では、図2の(B)→(C)、及び、図4の(A)→(B)に示す様に、上記第二中間素材20を構成する主板部13aの長さ方向両端部に増肉加工を施す事により、これら長さ方向両端部の板厚を増加させる事で、第三中間素材28を得る。この様な「増肉工程」の目的は、完成後の1対のフランジ部3a、4aに形成する通孔7及びねじ孔8(図1)の軸方向寸法を、必要量確保できる様にする事、並びに、後述する「曲げ工程」で形成する結合筒部2aの内周面に形成される部分円筒面部{雌セレーション6(図1)を形成する部位}の円周方向長さを、必要量確保できる様にする事にある。   Next, in the “thickening step”, as shown in FIG. 2 (B) → (C) and FIG. 4 (A) → (B), the main plate portion constituting the second intermediate material 20. The third intermediate material 28 is obtained by increasing the plate thickness at both ends in the length direction by applying a thickening process to both ends in the length direction 13a. The purpose of such a “thickening process” is to ensure the necessary amount of axial dimensions of the through holes 7 and the screw holes 8 (FIG. 1) formed in the pair of flange portions 3a, 4a after completion. In addition, the circumferential length of the partial cylindrical surface portion {the portion forming the female serration 6 (FIG. 1)} formed on the inner peripheral surface of the coupling cylinder portion 2a formed in the “bending step” described later is required. The amount is to be secured.
図4に示す様に、上記「増肉工程」で使用する装置(プレス機)は、ホルダ29と、ダイス22aと、上記絞りパンチ25(図3参照)と同形状のセンタークッション部材30と、1対のサイドクッション部材24a、24aと、1対の駆動カム31、31と、1対のスライドカム32、32と、1対の増肉パンチ33、33とを備える。上記主板部13aの長さ方向両端部に増肉加工を施す場合には、図4の(A)に示す様に、上記ホルダ29の底面上に設置した、上記ダイス22aの上面に、上記第二中間素材20を載せる。これと共に、図示しない1対の押え治具により、この第二中間素材20を構成する主板部13aの幅方向(図4の表裏方向)両側縁を押える。又、上記センタークッション部材30により、上記主板部13aの長さ方向中間部である上記絞り部21の上面(内周面)を押える(この絞り部21を、上記センタークッション30の下面に設けた凸部26aと、上記ダイス22aの上面に設けた凹部27aとの間で圧縮挟持する)。これと共に、上記センタークッション30の両側に配置した上記1対のサイドクッション部材24a、24aにより、上記主板部13aの上面のうち上記絞り部21の両側部分を押える。   As shown in FIG. 4, the apparatus (press machine) used in the “thickening step” includes a holder 29, a die 22 a, a center cushion member 30 having the same shape as the drawing punch 25 (see FIG. 3), A pair of side cushion members 24 a and 24 a, a pair of drive cams 31 and 31, a pair of slide cams 32 and 32, and a pair of thickening punches 33 and 33 are provided. When increasing the thickness of both ends of the main plate portion 13a in the length direction, the upper surface of the die 22a installed on the bottom surface of the holder 29, as shown in FIG. The second intermediate material 20 is placed. At the same time, a pair of pressing jigs (not shown) press both side edges of the main plate portion 13a constituting the second intermediate material 20 in the width direction (front and back direction in FIG. 4). Further, the center cushion member 30 presses the upper surface (inner peripheral surface) of the throttle portion 21 which is the middle portion in the length direction of the main plate portion 13 a (the throttle portion 21 is provided on the lower surface of the center cushion 30. The compression portion 26a is compressed and clamped between the convex portion 26a and the concave portion 27a provided on the upper surface of the die 22a. At the same time, the pair of side cushion members 24a and 24a disposed on both sides of the center cushion 30 press both side portions of the throttle portion 21 on the upper surface of the main plate portion 13a.
そして、この状態で、上記1対の増肉パンチ33、33により、上記主板部13aの長さ方向両端縁を強く押圧し、この主板部13aに長さ方向両側から圧縮力を加える事で、図4の(A)→(B)に示す様に、上記主板部13aの長さ方向両端部の板厚のみを、均一に増加させる。尚、本例の場合、上記ホルダ29の両内側面に沿って上下方向に変位可能な、上記1対の駆動カム31、31と、上記ダイス22aの上面に沿って図示の左右方向に変位可能な、上記1対のスライドカム32、32とを、互いのカム面34、35同士を摺動可能に接触させる事により、カム機構を構成している。そして、プレス機を構成する図示しないプレスラムの下方への変位力によって、上記両駆動カム31、31を下方に押圧する事により、上記両カム面34、35同士の接触部を介して、上記両スライドカム32、32を互いに近づき合う方向に押圧できる様にしている。そして、これら両スライドカム32、32により、上記両増肉パンチ33、33の背面を押圧する事に基づいて、これら両増肉パンチ33、33により、上記主板部13aの長さ方向両端縁を強く押圧できる様にしている。   In this state, the pair of thickening punches 33 and 33 strongly press both ends in the longitudinal direction of the main plate portion 13a, and by applying a compressive force to both sides of the main plate portion 13a in the length direction, As shown in FIGS. 4A to 4B, only the plate thicknesses at both ends in the length direction of the main plate portion 13a are increased uniformly. In the case of this example, the pair of drive cams 31, 31 that can be displaced in the vertical direction along both inner side surfaces of the holder 29 and the lateral direction in the drawing along the upper surface of the die 22a are possible. The cam mechanism is configured by bringing the pair of slide cams 32 and 32 into contact with each other so that the cam surfaces 34 and 35 are slidable. Then, both the drive cams 31, 31 are pressed downward by a downward displacement force of a press ram (not shown) constituting the press machine, whereby both the above cam surfaces 34, 35 are contacted with each other. The slide cams 32 and 32 can be pressed in a direction approaching each other. Based on the pressing of the back surfaces of the two thickening punches 33, 33 by the two slide cams 32, 32, both longitudinal edges of the main plate portion 13a are formed by the two thickening punches 33, 33. It can be pressed strongly.
尚、本例の場合には、上記主板部13aに加える圧縮力によって、この主板部13aの長さ方向両端部が座屈するのを防止しつつ、この長さ方向両端部の板厚を均一に増加させられる様にすべく、上記両サイドクッション部材24、24の初期のクッション力(上記主板部13aの上面を押える力)を、それぞれ29.4kN(3tonf)以上(例えば29.4kN)に設定している。尚、このクッション力を19.6kN(2tonf)以下に設定すると、上記長さ方向両端部が座屈するのを有効に防止できなくなる。これに対し、このクッション力を19.6kNを越えて過度に大きく設定すると、増肉に対する抵抗が大きくなって、上記長さ方向両端部の板厚を効果的に増加させられなくなる。この為、上記両サイドクッション部材24、24のクッション力は、それぞれ19.6kNを越える範囲で低めに(例えば上記29.4kN程度に)設定するのが好ましい。   In this example, the compressive force applied to the main plate portion 13a prevents the both end portions in the length direction of the main plate portion 13a from buckling, and the plate thickness at both end portions in the length direction is made uniform. In order to be increased, the initial cushioning force (force for pressing the upper surface of the main plate portion 13a) of the side cushion members 24, 24 is set to 29.4 kN (3 tonf) or more (for example, 29.4 kN). doing. If this cushioning force is set to 19.6 kN (2 tonf) or less, it will not be possible to effectively prevent buckling of both ends in the length direction. On the other hand, if this cushioning force is set to an excessively large value exceeding 19.6 kN, the resistance to thickening increases, and the plate thickness at both ends in the length direction cannot be effectively increased. For this reason, it is preferable that the cushioning force of both the side cushion members 24, 24 is set to be low (for example, about 29.4 kN) within a range exceeding 19.6 kN.
又、本例の場合には、上記圧縮力によって、上記絞り部21が座屈するのを防止すると共に、上記主板部13aの長さ方向両端部から上記絞り部21に向かう材料の流れを確実に堰き止めて、この絞り部21の形状を保持できる様にすべく、上記センタークッション部材30の初期のクッション力(上記絞り部21の上面を押える力)を、235.2kN(24tonf)以上(例えば235.2kN)に設定している。尚、このクッション力を78.4kN(8tonf)以下に設定すると、上記絞り部21が座屈するのを有効に防止できなくなる。この為、この絞り部21が座屈するのを防止する事だけを考えるのであれば、上記センタークッション部材30のクッション力は、78.4kNよりも大きく設定するだけで良い。但し、本例の場合には、このクッション力により、上記主板部13aの長さ方向両側からの材料の流れを堰き止めて、この主板部13aの長さ方向両端部の板厚を効果的に増加させられる様にする必要がある。この為、上記センタークッション部材30のクッション力は、上記235.2kN程度と大きく設定している。尚、本例の場合、上記両サイドクッション部材24、24及び上記センタークッション部材30のクッション力は、プレス機を構成する図示しないプレスラムの下方への変位力(プレス押圧力)を、方向変換せずに利用して(例えば適切なガススプリング、コイルスプリング等を選定し、これらによって所定の大きさに調節する事により)得ている。又、本例の場合には、上記圧縮力によって、上記主板部13aの幅寸法が増加するのを防止し、この主板部13aの長さ方向両端部の板厚を効果的に増加させられる様にすべく、図示しない1対の押え治具により、上記主板部13aの幅方向両側縁を、拡幅不能に押えている。   Further, in the case of this example, the compression portion prevents the throttle portion 21 from buckling, and ensures the flow of material from both ends in the length direction of the main plate portion 13a toward the throttle portion 21. The initial cushion force of the center cushion member 30 (the force for pressing the upper surface of the throttle portion 21) is 235.2 kN (24 tons) or more (for example, so that the shape of the throttle portion 21 can be maintained by damming. 235.2 kN). If the cushioning force is set to 78.4 kN (8 tonf) or less, it becomes impossible to effectively prevent the throttle portion 21 from buckling. For this reason, if only considering preventing the throttle portion 21 from buckling, the cushion force of the center cushion member 30 need only be set larger than 78.4 kN. However, in the case of this example, the cushioning force effectively blocks the material flow from both sides in the length direction of the main plate portion 13a, thereby effectively reducing the thickness of both ends in the length direction of the main plate portion 13a. It needs to be increased. For this reason, the cushioning force of the center cushion member 30 is set to be as large as about 235.2 kN. In the case of this example, the cushion force of the side cushion members 24, 24 and the center cushion member 30 changes the direction of the downward displacement force (press pressing force) of a press ram (not shown) constituting the press machine. (E.g., by selecting appropriate gas springs, coil springs, etc. and adjusting them to a predetermined size). In the case of this example, it is possible to prevent the width of the main plate portion 13a from increasing due to the compressive force, and to effectively increase the plate thickness at both ends in the length direction of the main plate portion 13a. Accordingly, both side edges in the width direction of the main plate portion 13a are pressed so as not to be widened by a pair of holding jigs (not shown).
又、本例の場合には、上記主板部13aに加える圧縮力を発生させる際に、上記ホルダ29の両内側面には、上記両駆動カム31、31を介して、大きな反力が加わる。この為、本例の場合には、上記ホルダ29を分割構造とせず、一体構造とする事で、このホルダ29が上記反力によって破損するのを防止できる様にしている。又、本例の場合、上記ダイス22aの幅方向中間部を、幅方向両端部に対して昇降可能な昇降部36としている。そして、上記ホルダ29内に設けたノックピン37aにより、上記昇降部36を介して、上記主板部13aの下面に弱いクッション力を加えている。上記増肉加工の終了後は、上記各クッション部材30、24が上昇するのと同時に、上記クッション力により上記昇降部36を上昇させる事で、前記第三中間素材28を取り出す。   In the case of this example, when generating a compressive force to be applied to the main plate portion 13 a, a large reaction force is applied to both inner side surfaces of the holder 29 via the drive cams 31, 31. For this reason, in the case of this example, the holder 29 is made not to be divided but to be integrated, so that the holder 29 can be prevented from being damaged by the reaction force. In the case of this example, the middle part in the width direction of the die 22a is a lifting part 36 that can be lifted and lowered relative to both ends in the width direction. A weak cushioning force is applied to the lower surface of the main plate portion 13a via the lifting / lowering portion 36 by a knock pin 37a provided in the holder 29. After the end of the thickening process, the third intermediate material 28 is taken out by raising the elevating part 36 by the cushion force at the same time that the cushion members 30 and 24 are raised.
尚、上述した様な「増肉工程」で、上記主板部13aの長さ方向両端部の板厚の増加量は、上記両厚肉パンチ33、33のストローク(及び、これら両厚肉パンチ33、33のストロークと相関関係がある、上記両駆動カム31、31のストローク、及び、これら両駆動カム31、31を取り付けた図示しないプレスラムのストローク、及び、このプレスラムのストロークと相関関係がある、プレス機のダイハイト)に、凡そ比例する。この為、上記長さ方向両端部の板厚の増加量は、プレス機のダイハイトを調整する事によって、容易に調整する事ができる。   In the “thickening step” as described above, the amount of increase in the plate thickness at both ends in the length direction of the main plate portion 13a is determined by the strokes of the thick punches 33, 33 (and the thick punches 33). There is a correlation with the strokes of the drive cams 31 and 31, the stroke of the press ram (not shown) to which the drive cams 31 and 31 are attached, and the stroke of the press ram. It is roughly proportional to the die height of the press. For this reason, the increase amount of the plate | board thickness of the said length direction both ends can be easily adjusted by adjusting the die height of a press machine.
次に、前記「腕部成形工程」では、図2の(C)→(D)に示す様に、上記第三中間素材28を構成する1対の舌片部14a、14aの根元部分に対し、これら各根元部分が、それぞれ先端側に向かう程絞り部21の中心軸から離れる方向に所定角度だけ傾斜した形状になる、プレス加工を施す。これにより、上記両舌片部14a、14aを1対の腕部5a、5aとした、第四中間素材38を得る。この様な「腕部成形工程」の目的は、上記両腕部5a、5aの外形を造る事、並びに、次述する「曲げ工程」で、これら両腕部5a、5aの側面が互いに平行に向き合い、適切な寸法だけ離れる様にする事にある。尚、上記両舌片部14a、14aの根元部分に上記プレス加工を施す際には、これら両根元部分が延びる。この為、この延びに伴って割れが発生するのを防止すべく、上記両舌片部14a、14aの先端側から圧縮力を加えつつ、上記プレス加工を施す様にする事もできる。又、上述した「増肉工程」で、腕部成形用のクッション部材を追加し、この「増肉工程」と上記「腕部成形工程」とを、1工程にまとめる事もできる。1工程にまとめれば、その分だけ製造コストを削減できる。   Next, in the “arm portion forming step”, as shown in FIGS. 2C to 2D, with respect to the root portions of the pair of tongue pieces 14a and 14a constituting the third intermediate material 28. Each of these root portions is pressed so as to be inclined by a predetermined angle in a direction away from the central axis of the narrowed portion 21 toward the tip side. As a result, a fourth intermediate material 38 is obtained in which the both tongue pieces 14a, 14a are formed as a pair of arms 5a, 5a. The purpose of such an “arm portion forming step” is to form the outer shape of the both arm portions 5a and 5a, and in the “bending step” described below, the side surfaces of both arm portions 5a and 5a are parallel to each other. Facing each other and leaving the appropriate dimensions. In addition, when performing the said press work to the base part of both said tongue piece parts 14a and 14a, these both base parts are extended. For this reason, in order to prevent a crack from being generated along with this extension, it is possible to apply the pressing while applying a compressive force from the distal end side of the tongue portions 14a, 14a. Further, in the above-described “thickening step”, a cushion member for forming the arm portion can be added, and the “thickening step” and the “arm portion forming step” can be combined into one step. If they are combined into one process, the manufacturing cost can be reduced accordingly.
次に、前記「曲げ工程」では、図2の(D)→(E)に示す様に、上記第四中間素材38を構成する主板部13aに設けた絞り部21を更に湾曲させる事により、第五中間素材39を得る。この様な第五中間素材39を得る為に、具体的には、上記第四中間素材38を構成する絞り部21の内径側に、図示しないマンドレルを嵌め込む。このマンドレルの外周面形状は、完成後の結合筒部2aの内周面形状に(雌セレーション形状を除き)合致する形状としている。そして、この状態で、上記第四中間素材38を図示しないダイスの内側に押し込む。これにより、この第四中間素材38を構成する主板部13aの長さ方向中間部を、更に湾曲させると共に、この主板部の長さ方向両端部を、それぞれ上記絞り部21の湾曲方向に立ち上げる。これにより、上記絞り部21を、上記マンドレルの外周面形状と合致する内周面形状を有する欠円筒状の結合筒部2aとし、且つ、上記主板部13aの長さ方向両端部を、互いにほぼ平行な1対のフランジ部3a、4aとして、上記第五中間素材39とする。   Next, in the “bending step”, as shown in (D) → (E) of FIG. 2, by further curving the narrowed portion 21 provided on the main plate portion 13 a constituting the fourth intermediate material 38, A fifth intermediate material 39 is obtained. In order to obtain such a fifth intermediate material 39, specifically, a mandrel (not shown) is fitted on the inner diameter side of the throttle portion 21 constituting the fourth intermediate material 38. The shape of the outer peripheral surface of this mandrel is a shape that matches the inner peripheral surface shape (except for the female serration shape) of the completed coupling cylinder portion 2a. In this state, the fourth intermediate material 38 is pushed into a die (not shown). As a result, the intermediate portion in the length direction of the main plate portion 13a constituting the fourth intermediate material 38 is further bent, and both end portions in the length direction of the main plate portion are raised in the bending direction of the throttle portion 21, respectively. . As a result, the narrowed portion 21 is formed as a non-cylindrical connecting tube portion 2a having an inner peripheral surface shape that matches the outer peripheral surface shape of the mandrel, and both end portions in the longitudinal direction of the main plate portion 13a are substantially mutually connected. The pair of parallel flange portions 3 a and 4 a is the fifth intermediate material 39.
尚、上記絞り部21に曲げ加工を施す際の割れ防止対策としては、この絞り部21を、その曲率半径がこの絞り部21の外周面の曲率半径よりも少しだけ小さいダイスに押し込んで、若干圧力をかけながら、上記絞り部21の曲げ加工を行う事が考えられる。同じく、別の割れ防止対策としては、上記絞り部21の曲げ加工を2回に分けて行う事が考えられる。この場合には、1回目の曲げ加工で、上記主板部13aの長さ方向両端部を、V字配置になるまで立ち上げる。そして、2回目の曲げ加工で、これら長さ方向両端部を、(これら長さ方向両端部の先端縁からパンチで圧縮力を加えながら、)互いにほぼ平行になるまで立ち上げる。又、上記曲げ加工の終了後、上記マンドレルは、上記結合筒部2aの内側から軸方向に抜き出す。   As a measure for preventing cracking when bending the drawn portion 21, the drawn portion 21 is pushed into a die whose radius of curvature is slightly smaller than the radius of curvature of the outer peripheral surface of the drawn portion 21. It is conceivable to perform the bending process of the narrowed portion 21 while applying pressure. Similarly, as another crack prevention measure, it is conceivable to perform the bending process of the drawn portion 21 in two steps. In this case, both ends in the length direction of the main plate portion 13a are raised up to the V-shaped arrangement in the first bending process. Then, in the second bending process, the two end portions in the length direction are raised until they are substantially parallel to each other (while applying a compressive force with a punch from the leading edge of the both end portions in the length direction). Moreover, after the end of the bending process, the mandrel is extracted in the axial direction from the inside of the coupling cylinder portion 2a.
そして、以上に述べた様な、図2の(A)〜(E)に示した各工程を終えたならば、次いで、上記第五中間素材39を構成する結合筒部2aの内周面に雌セレーション6を、同じく1対のフランジ部3a、4aに通孔7及びねじ孔8を、同じく1対の腕部5a、5aの先端部に円孔9、9を、それぞれ形成して、前記ヨーク1a(図1)を完成させる。   When the steps shown in FIGS. 2A to 2E as described above are completed, the inner peripheral surface of the coupling cylinder portion 2a constituting the fifth intermediate material 39 is then applied. The female serration 6 is formed with a through hole 7 and a screw hole 8 in the pair of flange portions 3a and 4a, and circular holes 9 and 9 are formed in the tip portions of the pair of arm portions 5a and 5a, respectively. The yoke 1a (FIG. 1) is completed.
上述した様な本例の自在継手用ヨークの製造方法によれば、素材となる金属板に打ち抜き加工を施す事により形成した第一中間素材12aを使用して、1対のフランジ部3a、4aの板厚を他の部位の板厚よりも大きくしたヨーク1aを、能率良く、しかも十分な精度を確保して造れる。   According to the method for manufacturing a universal joint yoke of this example as described above, a pair of flange portions 3a and 4a are used by using the first intermediate material 12a formed by stamping a metal plate as a material. The yoke 1a having a plate thickness larger than that of other portions can be made efficiently and with sufficient accuracy.
[実施の形態の第2例]
図5〜9は、請求項1、3に対応する、本発明の実施の形態の第2例を示している。本例の場合には、図5の(A)に示す第一中間素材12aから、同図の(B)に示す第三中間素材28aを得る方法が、上述した第1例の場合と異なる。即ち、上述した第1例の場合には、図2の(A)に示した第一中間素材12aに「絞り工程」の加工を施して、一旦、同図の(B)に示した第二中間素材20を得た後、この第二中間素材20に「増肉工程」の加工を施して、同図の(C)に示した第三中間素材28を得る。これに対し、本例の場合には、図5の(A)に示す第一中間素材12aに対し、上記「絞り工程」と上記「増肉工程」とを1工程にまとめた「絞り・増肉工程」の加工を施す事により、直接、同図の(B)に示す第三中間素材28aを得る。本例の場合には、この様な「絞り・増肉工程」で、上記「増肉工程」(図4参照)と同じ加工装置(プレス機)を使用する。
[Second Example of Embodiment]
5 to 9 show a second example of an embodiment of the present invention corresponding to claims 1 and 3. In the case of this example, the method of obtaining the third intermediate material 28a shown in FIG. 5B from the first intermediate material 12a shown in FIG. 5A is different from the case of the first example described above. That is, in the case of the first example described above, the first intermediate material 12a shown in FIG. 2A is processed in the “drawing step”, and then the second intermediate shown in FIG. After obtaining the intermediate material 20, the second intermediate material 20 is processed in the “thickening step” to obtain the third intermediate material 28 shown in FIG. On the other hand, in the case of this example, the “drawing / increasing step” in which the “drawing step” and the “thickening step” are combined into one step for the first intermediate material 12a shown in FIG. By applying the “meat process”, the third intermediate material 28a shown in FIG. In the case of this example, the same processing apparatus (press machine) as the above “thickening step” (see FIG. 4) is used in such a “drawing / thickening step”.
上記「絞り・増肉工程」を行う場合には、先ず、図6の(A)及び図7の(A)に示す様に、上記加工装置に上記第一中間素材12aをセットする。尚、図示は省略するが、1対のサイドクッション部材24a、24aを取り付けたプレスラムが上死端にある状態では、上記第一中間素材12aを載せたダイス22aの昇降部36が、ノックピン37aの弱いクッション力によって、図6の(A)及び図7の(A)に示す位置よりも、上方に浮き上がっている。そして、この様に浮き上がった状態から、上記プレスラムと共に上記両サイドクッション部材24a、24aを下方に変位させて、これら両サイドクッション部材24a、24aにより上記主板部13aの長さ方向両端寄り部分の上面を押えつつ、上記昇降部36を下降させて着座させた状態が、図6の(A)及び図7の(A)に示した状態である。   When the “drawing / thickening step” is performed, first, the first intermediate material 12a is set in the processing apparatus, as shown in FIGS. 6A and 7A. In addition, although illustration is omitted, in a state where the press ram to which the pair of side cushion members 24a and 24a are attached is at the top dead end, the elevating part 36 of the die 22a on which the first intermediate material 12a is placed is connected to the knock pin 37a. Due to the weak cushioning force, it floats upward from the position shown in FIG. 6 (A) and FIG. 7 (A). Then, the side cushion members 24a, 24a are displaced downward together with the press ram from the state of being lifted in this way, and the upper surfaces of the portions of the main plate portion 13a near both ends in the length direction are displaced by the side cushion members 24a, 24a. The state in which the elevating part 36 is lowered and seated while pressing is shown in FIGS. 6A and 7A.
上述の様に加工装置に第一中間素材12aをセットしたならば、次いで、図6の(A)→(B)の順、より具体的には、図7の(A)→(B)→(C)→(D)→(E)の順に示す様にして、上記第一中間素材12aに対し、「絞り・増肉工程」の加工を施す事により、上記第三中間素材28aを得る。下記の表1は、この様にして「絞り・増肉工程」の加工を施す際の、上記両サイドクッション部材24a、24aと、センタークッション部材30(絞りパンチ)と、1対の増肉パンチ33、33との挙動を示している。尚、下記の表1中、「状態1」は、図6の(A)及び図7の(A)に対応する状態を、「状態2」は、図7の(B)に対応する状態を、「状態3」は、図7の(C)に対応する状態を、「状態4」は、図7の(D)に対応する状態を、「状態5」は、図6の(B)及び図7の(E)に対応する状態を、それぞれ示している。
If the first intermediate material 12a is set in the processing apparatus as described above, then, in the order of (A) → (B) in FIG. 6, more specifically, (A) → (B) in FIG. As shown in the order of (C) → (D) → (E), the third intermediate material 28a is obtained by subjecting the first intermediate material 12a to the “drawing / thickening process”. Table 1 below shows both the side cushion members 24a, 24a, the center cushion member 30 (drawing punch), and a pair of thickening punches when the “drawing / thickening process” is performed in this manner. The behavior with 33 and 33 is shown. In Table 1 below, “State 1” indicates a state corresponding to (A) in FIG. 6 and FIG. 7 (A), and “State 2” indicates a state corresponding to (B) in FIG. , “State 3” is a state corresponding to FIG. 7C, “state 4” is a state corresponding to FIG. 7D, “state 5” is FIG. The states corresponding to (E) in FIG. 7 are shown.
上記各状態の意味は、次の通りである。先ず、図6の(A)及び図7の(A)に対応する「状態1」は、上記加工装置に上記第一中間素材12aをセットした状態を示している。この「状態1」では、上記両サイドクッション部材24a、24aにより、この第一中間素材12aを構成する主板部13aの長さ方向両端寄り部分の上面を押えている。更には、図示しない1対の押え治具により、上記主板部13aの幅方向(図6〜7の表裏方向)両端縁を拡幅不能に押えている。尚、上記両サイドクッション部材24a、24aのクッション力(上記主板部13aの上面を押える力)は、上述した第1例の「増肉工程」で設定したクッション力と同じ大きさになっている。又、この「状態1」では、上記センタークッション部材30及び上記両増肉パンチ33、33は、上記主板部13aに接触していない(微小隙間を介して近接している)か、或いは、接触していても無負荷の状態になっている。 The meanings of the above states are as follows. First, “State 1” corresponding to FIGS. 6A and 7A shows a state in which the first intermediate material 12a is set in the processing apparatus. In this “state 1”, the upper surfaces of both the side cushion members 24a, 24a hold the upper portions of the main plate portion 13a constituting the first intermediate material 12a closer to both ends in the length direction. Further, both ends of the main plate portion 13a in the width direction (front and back directions in FIGS. 6 to 7) are pressed so as not to be widened by a pair of holding jigs (not shown). In addition, the cushioning force (force for pressing the upper surface of the main plate portion 13a) of the side cushion members 24a, 24a is the same as the cushioning force set in the “thickening step” of the first example described above. . Further, in the “state 1”, the center cushion member 30 and the both thickening punches 33 and 33 are not in contact with the main plate portion 13a (close to each other through a minute gap) or are in contact with each other. Even if it is, it is in a no-load state.
次に、図7の(B)に対応する「状態2」は、上記センタークッション部材30により上記主板部13aの長さ方向中間部を上方から押し始めた状態、即ち、この長さ方向中間部の絞り加工を開始した状態を示している。この様に、上記両増肉パンチ33、33により上記主板部13aの増肉加工を開始する前に、上記絞り加工を開始する理由は、この絞り加工を開始する前に、上記増肉加工を開始すると、上記主板部13aの長さ方向中間部が、好ましくない方向(図6〜7の上方)に座屈する可能性がある為である。   Next, “State 2” corresponding to FIG. 7B is a state in which the center cushion member 30 starts pushing the intermediate portion in the longitudinal direction of the main plate portion 13a from above, that is, the intermediate portion in the longitudinal direction. This shows a state in which the drawing process is started. As described above, the reason for starting the drawing process before starting the thickening process of the main plate portion 13a by the both thickening punches 33, 33 is to perform the thickening process before starting the drawing process. This is because the lengthwise intermediate portion of the main plate portion 13a may buckle in an unfavorable direction (upward in FIGS. 6 to 7).
次に、図7の(C)に対応する「状態3」は、上記両増肉パンチ33、33により上記主板部13aの長さ方向両端縁を押し始めた状態、即ち、この主板部13aの増肉加工を開始し始めた状態を示している。この「状態3」では、未だ、上記絞り加工が終了していない。この絞り加工が終了するまでの間は、上記増肉加工によって、上記主板部13aの板厚が全体的に(この主板部13aの長さ方向中間部に形成された絞り部21aを含めて)ほぼ均一に増加する。尚、この「状態3」では、上記絞り加工と共に上記増肉加工を行える様にする為に、上記両増肉パンチ33、33の送り速度を、上記絞り加工に伴う、上記主板部13aの長さ寸法の減少速度よりも大きくする。   Next, "State 3" corresponding to (C) in FIG. 7 is a state in which the both end edges in the length direction of the main plate portion 13a are started to be pushed by the both thickening punches 33, 33, that is, the main plate portion 13a The state which started the thickening process is shown. In the “state 3”, the drawing process has not been completed yet. Until this drawing process is completed, the plate thickness of the main plate portion 13a is entirely increased (including the drawn portion 21a formed in the middle portion in the longitudinal direction of the main plate portion 13a) by the above-described thickening process. Increase almost uniformly. In this “state 3”, in order to perform the thickening process together with the drawing process, the feeding speed of the both thickening punches 33, 33 is set to the length of the main plate portion 13a associated with the drawing process. It is made larger than the reduction speed of the height dimension.
次に、図7の(D)に対応する「状態4」は、上記センタークッション部材30による絞り加工が終了し、且つ、上記両増肉パンチ33、33による増肉加工を続行している状態を示している。上記絞り加工が終了すると、上記主板部13aの長さ方向中間部に形成された絞り部21aの上面(内周面)が、上記センタークッション部材30により押えられた状態となる。この際のセンタークッション部材30のクッション力(上記絞り部21aの上面を押える力)は、上述した第1例の「増肉工程」で設定したクッション力と同じ大きさになっている。この為、上記絞り加工が終了した後は、上記主板部13aのうち、上記絞り部21aの板厚は増加せず、この絞り部21aの両側に存在する部分の板厚のみが、引き続き増加する。
次に、図6の(B)及び図7の(E)に対応する「状態5」は、上記両増肉パンチ33、33による増肉加工が終了し、第三中間素材28aが得られた状態を示している。
Next, “State 4” corresponding to FIG. 7D is a state in which the drawing process by the center cushion member 30 is completed and the thickening process by both the thickening punches 33 and 33 is continued. Is shown. When the drawing process is completed, the upper surface (inner peripheral surface) of the drawn portion 21a formed at the intermediate portion in the longitudinal direction of the main plate portion 13a is pressed by the center cushion member 30. At this time, the cushion force of the center cushion member 30 (force to press the upper surface of the throttle portion 21a) is the same as the cushion force set in the “thickening step” of the first example described above. For this reason, after the drawing process is completed, the plate thickness of the drawn portion 21a does not increase in the main plate portion 13a, and only the thickness of the portions existing on both sides of the drawn portion 21a continues to increase. .
Next, in “state 5” corresponding to FIG. 6B and FIG. 7E, the thickening process by both the thickening punches 33 and 33 is finished, and the third intermediate material 28a is obtained. Indicates the state.
尚、以上に述べた「絞り・増肉工程」で、上記絞り部21aの板厚の増加量は、プレス機のダイハイトを調整する事によって、容易に調整する事ができる。具体的には、先ず、このプレス機のダイハイトの大きさを、DH(1)にした場合と、DH(2)にした場合との、それぞれの場合に就いて、サンプル品に対し、上記「絞り・増肉工程」を試行する。そして、この試行後のサンプル品の絞り部21aの板厚T(1)、T(2)を測定し、図8の(A)に示す様な、上記ダイハイトと上記絞り部21aの板厚との間に成立する関係を求める。尚、この関係は、図示の様に比例関係となる。この理由は、図9に示す様に、上記「状態3」→「状態4」の間で、上記絞り部21aの板厚の増加量と、上記両増肉パンチ33、33の移動量との間に、比例関係が成立する為である。但し、計算上、この様な比例関係が成立するのは、本例の様に、上記主板部13aの板厚が、この主板部13aの長さ方向に関する上記絞り部21aの幅寸法よりも十分に小さい場合だけである。何れにしても、上記図8の(A)に示す様な関係を求めたならば、同図の(B)に示す様に、この関係を利用して、所望とする上記絞り部21aの板厚T(所望)から、この板厚T(所望)を実現する為の上記ダイハイトの大きさDH(調整)を決定する。従って、この様な方法で、このダイハイトの大きさを調整する事により、上記絞り部21aの板厚の増加量を調整できる。   In the above-described “drawing / thickening process”, the amount of increase in the thickness of the drawing portion 21a can be easily adjusted by adjusting the die height of the press. Specifically, first, in each case where the size of the die height of the press is DH (1) and DH (2), the above-mentioned “ Try "drawing / thickening process". Then, the plate thicknesses T (1) and T (2) of the throttle part 21a of the sample product after this trial are measured, and the die height and the plate thickness of the throttle part 21a as shown in FIG. Find the relationship that holds between the two. This relationship is proportional as shown in the figure. The reason for this is that, as shown in FIG. 9, between the “state 3” and “state 4”, the amount of increase in the thickness of the narrowed portion 21a and the amount of movement of both the thickening punches 33, 33 This is because a proportional relationship is established between them. However, in the calculation, such a proportional relationship is established because the thickness of the main plate portion 13a is sufficiently larger than the width dimension of the throttle portion 21a in the length direction of the main plate portion 13a as in this example. Only if it is small. In any case, if the relationship as shown in FIG. 8A is obtained, the desired plate of the diaphragm portion 21a is utilized using this relationship as shown in FIG. From the thickness T (desired), the die height size DH (adjustment) for realizing the plate thickness T (desired) is determined. Therefore, the amount of increase in the plate thickness of the narrowed portion 21a can be adjusted by adjusting the size of the die height by such a method.
上述した様な本例の場合には、前述した第1例の場合と異なり、第三中間素材28aを構成する主板部13aの長さ方向両端部の板厚だけでなく、この主板部13aの長さ方向中間部に形成した絞り部21aの板厚も増加させる事ができる。しかも、上記主板部13aの長さ方向両端部の板厚を、上記絞り部21aの板厚よりも大きくできる。尚、本例の場合には、上記第三中間素材28aを構成する絞り部21aの板厚を増加させた為、その後に形成する、図5の(C)に示す第四中間素材38aの絞り部21aの板厚、及び、図5の(D)に示す第五中間素材39aの結合筒部2bの板厚、及び、図示しない完成後のヨークを構成する結合筒部の板厚も、前述した第1例の場合に比べて大きくできる。その他の構成及び作用は、前述した第1例の場合と同様である。   In the case of this example as described above, unlike the case of the first example described above, not only the plate thickness at both ends in the length direction of the main plate portion 13a constituting the third intermediate material 28a, but also the main plate portion 13a. It is also possible to increase the thickness of the narrowed portion 21a formed in the middle portion in the length direction. Moreover, the plate thickness at both ends in the length direction of the main plate portion 13a can be made larger than the plate thickness of the throttle portion 21a. In the case of this example, since the plate thickness of the narrowed portion 21a constituting the third intermediate material 28a is increased, the diaphragm of the fourth intermediate material 38a shown in FIG. The plate thickness of the portion 21a, the plate thickness of the combined cylinder portion 2b of the fifth intermediate material 39a shown in FIG. 5D, and the plate thickness of the combined cylinder portion constituting the completed yoke (not shown) are also described above. This can be made larger than in the case of the first example. Other configurations and operations are the same as those of the first example described above.
[実施の形態の第3例]
図10〜11は、請求項1、4に対応する、本発明の実施の形態の第3例を示している。本例の場合には、先ず、前述した第1例と同じ方法で、図10の(A)に示す様な第一中間素材12aを得る。次いで、この第一中間素材12aに対し、「一発増肉工程」の加工を施す。この「一発増肉工程」では、図10の(A)→(B)、及び、図11の(A)→(B)に示す様に、上記第一中間素材12aを構成する主板部13aの長さ方向中間部と両端部とに増肉加工を施して、これら中間部と両端部との板厚を、これら各部位ごとに異なる大きさで(中間部の板厚<両端部の板厚、となる様に)増加させる事により、第二中間素材40を得る。
[Third example of embodiment]
FIGS. 10-11 has shown the 3rd example of embodiment of this invention corresponding to Claim 1,4. In the case of this example, first, the first intermediate material 12a as shown in FIG. 10A is obtained by the same method as the first example described above. Next, the first intermediate material 12a is subjected to the “one-thickening process”. In this “one-thickening process”, as shown in FIGS. 10A to 10B and FIGS. 11A to 11B, the main plate portion 13a constituting the first intermediate material 12a is formed. Thickening processing is applied to the intermediate part in the longitudinal direction and both end parts, and the thickness of the intermediate part and both end parts is set to a different size for each of these parts (the thickness of the intermediate part <the plate of both end parts The second intermediate material 40 is obtained by increasing the thickness.
図11に示す様に、上記「一発増肉工程」で使用する加工装置(プレス機)は、前述した第1例の「増肉工程」(図4参照)で使用する加工装置(プレス機)とほぼ同様であるが、センタークッション部材30aの下端面を、1対のサイドクッション部材24b、24bの下端面と同様、自身の中心軸に直角な平坦面としている点、並びに、ダイス22bの上面を全体的に平坦面としている点が異なる。又、上記「一発増肉工程」を行う場合も、前述した第1例の「増肉工程」(図4参照)を行う場合と同様、先ず、図11の(A)に示す様に、上記センタークッション部材30aと上記両サイドクッション部材24b、24bとにより、上記第一中間素材12aを構成する主板部13aの長さ方向中間部とその両側部分との上面を押える。これと共に、図示しない1対の押え治具により、上記主板部13aの幅方向(図11の表裏方向)両側縁を拡幅不能に押える。そして、この状態で、図11の(A)→(B)に示す様に、1対の増肉パンチ33、33により、上記主板部13aの長さ方向両端縁を強く押圧し、この主板部13aに長さ方向両側から圧縮力を加える事で、上記主板部13aの長さ方向中間部と両端部との板厚を、それぞれこれら各部位ごとに異なる大きさで(中間部の板厚<両端部の板厚、となる様に)で均一に増加させる。   As shown in FIG. 11, the processing apparatus (press machine) used in the “one-thickening process” is the processing apparatus (press machine) used in the “thickening process” (see FIG. 4) of the first example described above. ), But the lower end surface of the center cushion member 30a is a flat surface perpendicular to the center axis of the center cushion member 30a, like the lower end surfaces of the pair of side cushion members 24b and 24b, and the die 22b The difference is that the upper surface is entirely flat. Also, when performing the above-mentioned “one-thickening process”, as in the case of performing the “thickening process” (see FIG. 4) of the first example, first, as shown in FIG. The center cushion member 30a and the side cushion members 24b and 24b hold the upper surfaces of the intermediate portion in the longitudinal direction of the main plate portion 13a constituting the first intermediate material 12a and both side portions thereof. At the same time, a pair of pressing jigs (not shown) press both side edges of the main plate portion 13a in the width direction (front and back direction in FIG. 11) so as not to be widened. In this state, as shown in FIG. 11 (A) → (B), both ends of the main plate portion 13a in the longitudinal direction are strongly pressed by a pair of thickening punches 33, 33, and the main plate portion By applying a compressive force to both sides of the main plate portion 13a, the plate thicknesses of the main plate portion 13a in the length direction intermediate portion and both end portions are set to different sizes for the respective portions (plate thickness of the intermediate portion < Increase the thickness uniformly so that the thickness of both ends is equal.
この様に本例の場合には、上記圧縮力によって上記主板部13aの長さ方向両端部だけでなく、長さ方向中間部の板厚も増加させる事ができる様にする為に、上記センタークッション部材30aのクッション力(上記主板部13aの上面を押える力)を、前述した第1例の「増肉工程」(図4参照)で設定したクッション力よりも(所望の板厚の増加を実現できる分だけ)小さくしている。更に、本例の場合には、上記圧縮力によって、上記主板部13aの長さ方向両端部の板厚の増加量を、長さ方向中間部の板厚の増加量よりも多くする為に、上記両サイドクッション部材24b、24bのクッション力を、上記センタークッション部材30aのクッション力よりも小さくしている。   Thus, in the case of this example, in order to be able to increase not only the length direction both ends of the main plate portion 13a but also the plate thickness of the middle portion in the length direction by the compression force, The cushioning force of the cushion member 30a (the force for pressing the upper surface of the main plate portion 13a) is set to a value greater than the cushioning force set in the “thickening step” (see FIG. 4) of the first example described above. As much as it can be realized). Furthermore, in the case of this example, in order to increase the amount of increase in the plate thickness at both ends in the length direction of the main plate portion 13a by the compression force, the amount of increase in the plate thickness at the intermediate portion in the length direction is increased. The cushion force of both the side cushion members 24b, 24b is made smaller than the cushion force of the center cushion member 30a.
尚、本例の場合とは異なるが、上記センタークッション部材30aのクッション力を235.2kN(24tonf)以上にし、且つ、上記両サイドクッション部材24b、24bのクッション力を、それぞれ29.4kN(3tonf)にすると、上記主板部13aの長さ方向中間部の板厚は増加せず、長さ方向両端部の板厚のみが増加する。
又、上記センタークッション部材30aのクッション力を235.2kNよりも小さくし、上記両サイドクッション部材24b、24bのクッション力を、それぞれ29.4kNにすると、本例の様に、上記主板部13aの長さ方向両端部の板厚だけでなく、長さ方向中間部の板厚も(この長さ方向両端部の板厚よりも少ない割合で)増加する。
又、本例の場合とは異なるが、上記センタークッション部材30aのクッション力よりも、上記両サイドクッション部材24b、24bのクッション力を大きくすると、上記主板部13aの長さ方向中間部の板厚の増加量が、長さ方向両端部の板厚の増加量よりも多くなる。
但し、何れの場合も、上記センタークッション部材30a及び上記両サイドクッション部材24b、24bのクッション力は、上記主板部13aに加える圧縮力によって、この主板部13aが座屈するのを防止できる大きさにする。
Although different from the case of this example, the cushioning force of the center cushion member 30a is set to 235.2kN (24tonf) or more, and the cushioning forces of the both side cushion members 24b and 24b are respectively 29.4kN (3tonf). ), The plate thickness of the intermediate portion in the length direction of the main plate portion 13a does not increase, and only the plate thicknesses at both ends in the length direction increase.
Further, when the cushioning force of the center cushion member 30a is made smaller than 235.2kN and the cushioning force of the both side cushion members 24b and 24b is 29.4kN, respectively, as in this example, the main plate portion 13a Not only the plate thickness at both ends in the length direction but also the plate thickness at the middle portion in the length direction (at a rate smaller than the plate thickness at both ends in the length direction) is increased.
Further, although different from the case of this example, if the cushioning force of the side cushion members 24b and 24b is made larger than the cushioning force of the center cushion member 30a, the plate thickness of the intermediate portion in the longitudinal direction of the main plate portion 13a. The amount of increase becomes greater than the amount of increase in plate thickness at both ends in the length direction.
However, in any case, the cushioning force of the center cushion member 30a and the side cushion members 24b and 24b is such that the main plate portion 13a can be prevented from buckling due to the compressive force applied to the main plate portion 13a. To do.
以上の様に、上記センタークッション部材30aのクッション力と、上記両サイドクッション部材24b、24bのクッション力との間に差を付ける事により、この差に応じた分だけ、上記主板部13aの長さ方向中間部の板厚と、長さ方向両端部の板厚との間に、差を付ける事ができる。但し、クッション力と板厚との関係は、多少複雑である為、増肉加工の途中でクッション力の変更を頻繁に行う場合は、クッション力の変更を行い易い、油圧機構を使用するのが好ましい(上述した実施の形態の第1〜2例の場合に就いても同様である)。   As described above, by making a difference between the cushioning force of the center cushion member 30a and the cushioning force of the side cushion members 24b and 24b, the length of the main plate portion 13a is increased by an amount corresponding to the difference. A difference can be made between the thickness of the middle portion in the length direction and the thickness of both end portions in the length direction. However, the relationship between the cushioning force and the plate thickness is somewhat complicated, so if you frequently change the cushioning force during the thickening process, use a hydraulic mechanism that makes it easy to change the cushioning force. It is preferable (the same applies to the first and second examples of the embodiment described above).
何れにしても、上述した様な「一発増肉工程」が終了したならば、次いで、図10の(B)→(C)に示す様に、上記第二中間素材40に対し、前述の第1例の場合と同様の「腕部成形工程」の加工を施す事により、第三中間素材41を得る。次いで、図10の(C)→(D)示す様に、上記第三中間素材41に対し、前述の第1例の場合とほぼ同様の「曲げ工程」の加工を施す事により、第五中間素材39aを得る。但し、本例の場合には、上記第三中間素材41を構成する主板部13aの長さ方向中間部に、部分円筒状の絞り部が形成されていない為、上記「曲げ工程」を行う際の割れ防止対策として、前述の第1例で説明した、曲げ加工を2回に分けて行う方法を採用するのが好ましい。その他の構成及び作用は、前述した第1例の場合と同様である。   In any case, when the “one-thickening process” as described above is completed, then, as shown in FIG. The third intermediate material 41 is obtained by performing the same “arm forming process” as in the first example. Next, as shown in FIG. 10 (C) → (D), the third intermediate material 41 is subjected to the same “bending process” as in the first example described above, so that the fifth intermediate material 41 is processed. The material 39a is obtained. However, in the case of this example, since the partial cylindrical throttle part is not formed in the longitudinal direction intermediate part of the main plate part 13a constituting the third intermediate material 41, when performing the "bending step" As a countermeasure for preventing cracking, it is preferable to employ the method of performing the bending process in two steps as described in the first example. Other configurations and operations are the same as those of the first example described above.
尚、上述した各実施の形態では、前述の図1に示したヨーク1aの様に、1枚の金属板により全体を一体に形成したヨークを製造対象とした。但し、本発明は、例えば特許文献3に記載されている様な、1対の腕部を備えた先半部と、結合筒部及び1対のフランジ部を備えた基半部とを、互いに結合固定して成るヨークのうち、この基半部を製造対象として実施する事もできる。   In each of the above-described embodiments, a yoke that is integrally formed of a single metal plate as the yoke 1a shown in FIG. However, in the present invention, for example, as described in Patent Document 3, a front half portion having a pair of arm portions and a base half portion having a coupling cylinder portion and a pair of flange portions are mutually connected. Of the yokes that are coupled and fixed, this base half can also be implemented as a manufacturing object.
本発明の実施の形態の第1例の製造対象となるヨークを示しており、(A)は平面図、(B)は(A)の右方から見た図、(C)は(A)の下方から見た図。BRIEF DESCRIPTION OF THE DRAWINGS The yoke used as the manufacture object of the 1st example of embodiment of this invention is shown, (A) is a top view, (B) is the figure seen from the right side of (A), (C) is (A). The figure seen from below. 各製造工程で造られる中間素材を、これら各製造工程順に示す図。The figure which shows the intermediate material produced in each manufacturing process in order of these each manufacturing process. 「絞り工程」の実施状況を示す断面図。Sectional drawing which shows the implementation condition of a "drawing process". 「増肉工程」の実施状況を示す断面図。Sectional drawing which shows the implementation condition of a "thickening process". 本発明の実施の形態の第2例を示す、図2と同様の図。The figure similar to FIG. 2 which shows the 2nd example of embodiment of this invention. 「絞り・圧縮工程」の実施状況を、最初と最後とのみを簡単に示す断面図。Sectional drawing which shows the implementation condition of a "drawing / compression process" simply and only the first and last. 「絞り・圧縮工程」の実施状況を途中も含めて示す断面図。Sectional drawing which shows the implementation condition of a "drawing / compression process" including the middle. プレス機のダイハイトと被加工物の板厚との間に成立する関係を利用して、所望の板厚を得る為のダイハイトの大きさを決定する方法を説明する為の線図。The diagram for demonstrating the method of determining the magnitude | size of the die height for obtaining desired plate | board thickness using the relationship established between the die height of a press machine and the plate | board thickness of a workpiece. 増肉パンチの移動量と絞り部の板厚の増加量との関係を示すグラフ。The graph which shows the relationship between the movement amount of a thickening punch, and the increase amount of the plate | board thickness of a throttle part. 本発明の実施の形態の第3例を示す、図2と同様の図。The figure similar to FIG. 2 which shows the 3rd example of embodiment of this invention. 「一発増肉工程」の実施状況を示す断面図。Sectional drawing which shows the implementation condition of a "one shot thickening process". 従来から知られているヨークの1例を示しており、(A)は平面図、(B)は(A)のX−X断面図、(C)は(A)の下方から見た側面図。1 shows an example of a conventionally known yoke, (A) is a plan view, (B) is a sectional view taken along line XX of (A), and (C) is a side view as viewed from below (A). . 各製造工程で造られる中間素材を、これら各製造工程順に示す図。The figure which shows the intermediate material produced in each manufacturing process in order of these each manufacturing process. 従来から知られている、金属板素材の一部の板厚を増加する方法の1例を、工程順に示す断面図。Sectional drawing which shows one example of the method of increasing the plate | board thickness of a part of metal plate raw material known conventionally from process order.
符号の説明Explanation of symbols
1、1a ヨーク
2、2a、2b 結合筒部
3、3a フランジ部
4、4a フランジ部
5、5a 腕部
6 雌セレーション
7 通孔
8 ねじ孔
9 円孔
10 十字軸
11 軸受カップ
12、12a 第一中間素材
13、13a 主板部
14、14a 舌片部
15 第二中間素材
16 第三中間素材
17 金属板素材
18 曲げ起こし部
19 厚肉部
20 第二中間素材
21、21a 絞り部
22、22a、22b ダイス
23 ホルダ
24、24a、24b サイドクッション部材
25 絞りパンチ
26、26a 凸部
27、27a 凹部
28、28a 第三中間素材
29 ホルダ
30、30a センタークッション部材
31 駆動カム
32 スライドカム
33 増肉パンチ
34 カム面
35 カム面
36 昇降部
37、37a ノックピン
38、38a 第四中間素材
39、39a 第五中間素材
40 第二中間素材
41 第三中間素材
DESCRIPTION OF SYMBOLS 1, 1a Yoke 2, 2a, 2b Coupling cylinder part 3, 3a Flange part 4, 4a Flange part 5, 5a Arm part 6 Female serration 7 Through hole 8 Screw hole 9 Circular hole 10 Cross shaft 11 Bearing cup 12, 12a 1st Intermediate material 13, 13a Main plate part 14, 14a Tongue piece part 15 Second intermediate material 16 Third intermediate material 17 Metal plate material 18 Bending part 19 Thick part 20 Second intermediate material 21, 21a Restricted part 22, 22a, 22b Die 23 Holder 24, 24a, 24b Side cushion member 25 Drawing punch 26, 26a Convex part 27, 27a Concave part 28, 28a Third intermediate material 29 Holder 30, 30a Center cushion member 31 Drive cam 32 Slide cam 33 Thickening punch 34 Cam Surface 35 Cam surface 36 Elevating part 37, 37a Knock pin 38, 38a Fourth intermediate element 39,39a fifth intermediate material 40 second intermediate material 41 a third intermediate material

Claims (5)

  1. 素材となる金属板に打ち抜き加工を施す事により、少なくとも長矩形状の主板部を備えた中間素材を造った後、この主板部の長さ方向中間部を湾曲させる事により、この長さ方向中間部を、自在継手用ヨークを構成する欠円筒状の結合筒部とし、且つ、上記主板部の長さ方向両端部をそれぞれ、この結合筒部の円周方向両端縁から連続して形成された、上記自在継手用ヨークを構成する1対のフランジ部とする、自在継手用ヨークの製造方法に於いて、上記結合筒部を完成させる前に、上記主板部の各部分に、これら各部分毎に設定した所定の大きさのクッション力を、これら各部分の厚さ方向に加えながら、上記主板部に長さ方向両側から圧縮力を加える増肉加工を施す事により、この圧縮力に基づいてこの主板部が座屈するのを防止すると共に、この主板部の各部分の板厚の増加量を調整しつつ、この主板部の長さ方向両端部の板厚を、この主板部の長さ方向中間部の板厚と異なる大きさに増加させる事を特徴とする自在継手用ヨークの製造方法。   After making an intermediate material with at least a long rectangular main plate by punching the metal plate that is the material, this intermediate portion in the longitudinal direction is curved by bending the intermediate portion in the longitudinal direction of the main plate. And a cylindrical connecting tube portion constituting a universal joint yoke, and both end portions in the length direction of the main plate portion are continuously formed from both circumferential edges of the connecting tube portion, In the method of manufacturing a universal joint yoke, which is a pair of flange portions constituting the universal joint yoke, before the coupling cylinder portion is completed, each portion of the main plate portion is provided for each of these portions. By applying a thickening process that applies a compressive force from both sides in the longitudinal direction to the main plate part while applying a set cushioning force of a predetermined size in the thickness direction of each of these parts, Prevents the main plate from buckling In both cases, while adjusting the amount of increase in the thickness of each portion of the main plate portion, the plate thickness at both ends in the length direction of the main plate portion is set to a size different from the thickness of the intermediate portion in the length direction of the main plate portion. A method of manufacturing a universal joint yoke, characterized in that the yoke is increased.
  2. 増肉加工を施す前に、主板部の長さ方向中間部に絞り加工を施す事により、この長さ方向中間部を完成後の結合筒部と同方向に湾曲した部分円筒状に変形させた後、この長さ方向中間部の形状を保持する為に、この長さ方向中間部に対し、この長さ方向中間部の両側からこの長さ方向中間部に向かう材料の流れを確実に堰き止められる大きさのクッション力を加えながら、上記増肉加工を施す、請求項1に記載した自在継手用ヨークの製造方法。   Before applying the thickening process, the lengthwise intermediate part was deformed into a partially cylindrical shape curved in the same direction as the combined cylinder part after completion by drawing the lengthwise intermediate part of the main plate part. After that, in order to maintain the shape of the intermediate portion in the longitudinal direction, the material flow from both sides of the intermediate portion in the longitudinal direction to the intermediate portion in the longitudinal direction is reliably blocked against the intermediate portion in the longitudinal direction. The method for manufacturing a universal joint yoke according to claim 1, wherein the thickening process is performed while applying a cushioning force of a size that can be obtained.
  3. 主板部の長さ方向中間部に、この長さ方向中間部を完成後の結合筒部と同方向に湾曲した部分円筒状に変形させる絞り加工を施し始めるのと同時に、又は、この絞り加工の途中から、増肉加工を開始する事により、この増肉加工の開始後、上記絞り加工が終了する迄の間中、上記主板部の板厚を、この主板部の長さ方向両端部と長さ方向中間部とで互いに同じ割合で増加させると共に、上記絞り加工が終了した後、上記主板部の長さ方向中間部の形状を保持する為に、この絞り加工で使用したダイスと絞りパンチとを用いて、この長さ方向中間部に対し、この長さ方向中間部の両側からこの長さ方向中間部に向かう材料の流れを確実に堰き止められる大きさのクッション力を加えながら、上記増肉加工を続行する事により、上記主板部の長さ方向両端部の板厚を、この主板部の長さ方向中間部の板厚よりも大きな値にまで増加させる、請求項1に記載した自在継手用ヨークの製造方法。   At the same time as starting the drawing process for deforming the intermediate part in the longitudinal direction of the main plate part into a partial cylindrical shape that is curved in the same direction as the combined cylinder part after completion, or By starting the thickening process from the middle, the thickness of the main plate part is set to the length of both ends of the main plate part in the longitudinal direction until the drawing process is completed after the start of the thickening process. The die used in the drawing and the drawing punch are used to increase the length of the intermediate portion in the longitudinal direction at the same rate and to maintain the shape of the intermediate portion in the longitudinal direction of the main plate after the drawing. The above-mentioned increase is applied to the longitudinal intermediate portion while applying a cushioning force large enough to reliably block the flow of material from both sides of the longitudinal intermediate portion toward the longitudinal intermediate portion. By continuing meat processing, the length of the main plate The thickness of the direction both end portions, the main plate than the plate thickness in the longitudinal direction intermediate portion of the increase to a large value, a manufacturing method for a universal joint yoke according to claim 1.
  4. 主板部の長さ方向中間部とその両側部分とに、互いに異なる大きさのクッション力を加えながら増肉加工を行う事により、上記主板部の長さ方向中間部の板厚と、長さ方向両端部の板厚とを、それぞれ増加させると共に、この長さ方向中間部の板厚の増加量と、この長さ方向両端部の板厚の増加量とを、互いに異ならせる、請求項1に記載した自在継手用ヨークの製造方法。   By increasing the thickness of the main plate part in the length direction intermediate part and both side parts while applying cushioning forces of different sizes, the thickness of the main plate part in the length direction intermediate part and the length direction The plate thicknesses at both ends are increased, and the amount of increase in the plate thickness at the intermediate portion in the length direction is made different from the amount of increase in the plate thickness at both ends in the length direction. A method of manufacturing the described universal joint yoke.
  5. 主板部の各部分に加えるクッション力は、この主板部をダイスの上面に載せた状態で、この主板部の上面の各部分をクッション部材若しくは絞りパンチにより押圧する事に基づいて発生させるものであり、このクッション部材若しくは絞りパンチを押圧する力は、プレス機を構成するプレスラムの下方への変位力を、方向変換せずに得る力であり、
    上記主板部に加える圧縮力は、この主板部の長さ方向両端縁を1対の増肉パンチにより押圧する事に基づいて発生させるものであり、これら両増肉パンチを押圧する力は、上記プレスラムの下方への変位力を、水平方向の変位力に変換する事により得る力である、
    請求項1〜4のうちの何れか1項に記載した自在継手用ヨークの製造方法。
    The cushioning force applied to each portion of the main plate portion is generated based on pressing each portion of the upper surface of the main plate portion with a cushion member or a drawing punch while the main plate portion is placed on the upper surface of the die. The force that presses the cushion member or the squeeze punch is a force that obtains the downward displacement force of the press ram constituting the press machine without changing the direction,
    The compressive force applied to the main plate portion is generated based on pressing both ends of the main plate portion in the longitudinal direction with a pair of thickening punches. This is the force obtained by converting the downward displacement force of the press ram into a horizontal displacement force.
    The manufacturing method of the yoke for universal joints in any one of Claims 1-4.
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